DODGE DURANGO 1999 1.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Fig. 13 Securing Timing Chain Tensioners Using Timing Chain Wedge
1 ± LEFT CYLINDER HEAD
2 ± RIGHT CYLINDER HEAD3 ± SPECIAL TOOL 8350 WEDGE
4 ± SPECIAL TOOL 8350 WEDGE
Fig. 12 Camshaft Sprocket V8 Marks
1 ± LEFT CYLINDER HEAD
2 ± RIGHT CYLINDER HEAD
DN4.7L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine TIMING CHAINÐMEASURING WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the timing chain cover. Refer to Timing
Chain Cover in this section for procedure.
(2) To determine if the secondary timing chains
are worn, rotate the engine clockwise until maximum
tensioner piston extension is obtained. Measure the
distance between the secondary timing chain ten-
sioner housing and the step ledge on the piston (Fig.
17). The measurement at point (A) must be less than
15mm (.5906 inches).
(3) If the measurement exceeds the specification
the secondary timing chains are worn and require
replacement. Refer to Timing Chain and Sprockets in
this section for procedure.
PISTONSÐFITTING
BORE GAGE METHOD
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm
(.0001 in.) INCREMENTS is required. If a bore
gauge is not available, do not use an inside microme-
ter.
(2) Measure the inside diameter of the cylinder
bore at a point 49.5 mm (1-15/16 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then takean additional bore reading 90 degrees to that at point
B (Fig. 19).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled. Tin
coated pistons should not be used as replacements for
coated pistons.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 18). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
Fig. 14 Camshaft Dowel To Sprocket Alignment
1 ± ADJUSTABLE PLIERS
2 ± CAMSHAFT DOWEL
Fig. 15 Camshaft Sprocket InstallationÐLeft
Cylinder Head
1 ± TORQUE WRENCH
2 ± CAMSHAFT SPROCKET
3 ± LEFT CYLINDER HEAD
4 ± SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 22 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine Fig. 16 Camshaft Sprocket InstallationÐRight
Cylinder Head
1 ± TORQUE WRENCH
2 ± SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 ± LEFT CAMSHAFT SPROCKET
4 ± RIGHT CAMSHAFT SPROCKET
Fig. 17 Measuring Secondary Timing Chains For
Stretch
1 ± SECONDARY TENSIONER ARM
2 ± SECONDARY CHAIN TENSIONER PISTON
Fig. 18 Moly Coated Piston
1 ± MOLY COATED
2 ± MOLY COATED
Fig. 19 Bore GaugeÐTypical
1 ± FRONT
2 ± BORE GAUGE
3 ± CYLINDER BORE
4 ± 49.5 MM
(1±15/16 in)
DN4.7L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine PISTON RINGSÐFITTING
RING END GAP
Before reinstalling used rings or installing new
rings, the ring clearances must be checked.
(1) Wipe the cylinder bore clean.
(2) Insert the ring in the cylinder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is
squared in the cylinder bore, slide the ring downward
into the cylinder.
(4) Using a feeler gauge check the ring end gap
(Fig. 20). Replace any rings not within specification.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ring side clearance as shown (Fig.
21) make sure the feeler gauge fits snugly between
the ring land and the ring. Replace any ring not
within specification.
(6) Rotate the ring around the piston, the ring
must rotate in the groove with out binding.
EARLY BUILD
(7) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston.
LATE BUILD
The No. 1 and No. 2 piston rings have a different
cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (Dot) facing up, towards top
of the piston. On late build engines the piston top
ring groove and crown are not anodized therefore,
the No. 1 piston ring is coated with an anti-friction
coating. Care must be used to ensure that wheninstalling piston rings on late build engines that the
correct No. 1 piston ring be installed, failure to use
the correct piston ring can cause severe damage to
the piston and/or cylinder block.
Fig. 20 Ring End Gap MeasurementÐTypical
1 ± FEELER GAUGE
Fig. 21 Measuring Piston Ring Side Clearance
1 ± FEELER GAUGE
PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020-.0037
in.)(0.004 in.)
Intermediate
Ring0.04-0.08mm 0.10mm
(0.0016-0.0031
in.)(0.004 in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090 in.) (0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.20-0.36mm 0.40mm
(0.008-0.014 in.) (0.0016in.)
Intermediate
Ring0.37-0.63mm 0.71mm
(0.014-0.025 in.) (0.028in.)
Oil Control Ring 0.025-0.76mm 1.52mm
(Steel Rail) (0.010- 0.030
in.)(0.060in.)
9 - 24 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine NOTE: Piston rings are installed in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(8) Install the oil ring expander.
(9) Install upper side rail (Fig. 22) by placing one
end between the piston ring groove and the expander
ring. Hold end firmly and press down the portion to
be installed until side rail is in position. Repeat this
step for the lower side rail.
(10) Install No. 2 intermediate piston ring using a
piston ring installer (Fig. 23).
(11) Install No. 1 upper piston ring using a piston
ring installer (Fig. 23).
(12) Position piston ring end gaps as shown in
(Fig. 24). It is important that expander ring gap is at
least 45É from the side rail gaps, but not on the pis-
ton pin center or on the thrust direction.
CONNECTING ROD BEARINGSÐFITTING
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Fig. 25) (Fig. 26). Check the
bearings for normal wear patterns, scoring, grooving,
fatigue and pitting (Fig. 27). Replace any bearing
that shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
necting rod journals. If wear patterns or damage to
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rodalignment. Replace misaligned, bent or twisted con-
necting rods.
(1) Wipe the oil from the connecting rod journal.
(2) Lubricate the upper bearing insert and install
in connecting rod.
(3) Use piston ring compressor and Guide Pins
Special Tool 8507 (Fig. 28) to install the rod and pis-
ton assemblies. The oil slinger slots in the rods must
face front of the engine. The ªFº's near the piston
wrist pin bore should point to the front of the engine.
(4) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
Fig. 22 Side RailÐInstallation
1 ± SIDE RAIL END
Fig. 23 Upper and Intermediate RingsÐInstallation
Fig. 24 Piston Ring End Gap Position
1 ± SIDE RAIL UPPER
2 ± NO. 1 RING GAP
3 ± PISTON PIN
4 ± SIDE RAIL LOWER
5 ± NO. 2 RING GAP AND SPACER EXPANDER GAP
DN4.7L ENGINE 9 - 25
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (5) Install bearing cap and connecting rod on the
journal and tighten bolts to 27 N´m (20 ft. lbs.) plus a
90É turn. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(6) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 29). Refer to
Engine Specifications for the proper clearance.Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) If the correct clearance is indicated, replace-
ment of the bearing inserts is not necessary. Remove
the Plastigage from crankshaft journal and bearing
insert. Proceed with installation.
(8) If bearing-to-journal clearance exceeds the
specification, determin which services bearing set to
use the bearing sizes are as follows:
Fig. 25 Connecting Rod Bearing Inspection
1 ± UPPER BEARING HALF
2 ± MATING EDGES
3 ± GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 ± WEAR PATTERN Ð ALWAYS GREATER ON UPPER
BEARING
5 ± LOWER BEARING HALF
Fig. 26 Locking Tab Inspection
1 ± ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 27 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Fig. 28 Piston and Connecting RodÐInstallation
1 ± ªFº TOWARD FRONT OF ENGINE
2 ± OIL SLINGER SLOT
3 ± RING COMPRESSOR
4 ± SPECIAL TOOL 8507
9 - 26 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (9) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(10) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 27 N´m (20 ft. lbs.) plus a 90É turn.
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 30).
Refer to Engine Specifications for the proper clear-
ance. Replace the connecting rod if the side clearance
is not within specification.
CRANKSHAFT MAIN BEARINGS
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 31).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block.
Refer to Crankshaft in this section for procedure.
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.002
inch). Compare the measured diameter with the jour-
Fig. 29 Measuring Bearing Clearance with
Plastigage
1 ± PLASTIGAGE SCALE
2 ± COMPRESSED PLASTIGAGE
Bearing
MarkSIZE USED WITH
JOURNAL SIZE
.025 US.025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std.STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US.250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
Fig. 30 Checking Connecting Rod Side ClearanceÐ
Typical
Fig. 31 Main Bearing Wear Patterns
1 ± UPPER INSERT
2 ± NO WEAR IN THIS AREA
3 ± LOW AREA IN BEARING LINING
4 ± LOWER INSERT
DN4.7L ENGINE 9 - 27
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
Install the crankshaft into the cylinder block. Refer
to Crankshaft in this section for procedure.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in three
grades. The chart below identifies the three service
grades available.
REMOVAL AND INSTALLATION
ENGINE MOUNTSÐLEFT AND RIGHT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and
fan shroud before raising engine. Failure to do so
may cause damage to the fan blade, fan clutch and
fan shroud.
(2) Remove the fan blade, fan clutch and fan
shroud. Refer to Group 7. for procedure.
(3) Remove the engine oil filter.
(4) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
(5) Remove the four (4) cylinder block-to-insulator
mount bolts and the nut from the engine insulator
mount through bolt (4x2 Vehicles only) (Fig. 32) (Fig.
33).
(6) Remove the three (3) cylinder block-to-insulator
mount bolts and loosen the nut from the engine insu-
lator mount through bolt (4x4 Vehicles only) (Fig. 34)
(Fig. 35).
(7) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount.
INSTALLATION
(1) Position the insulator mount and install the
insulator mount through bolt.
(2) Lower the engine until the four cylinder block-
to-insulator mount bolts can be installed.
(3) Remove the jack and block of wood.
(4) Torque the cylinder block-to-insulator mount
bolts to 61N´m ( 45 ft. lbs.).
(5) Install and torque the through bolt retaining
nut to 61N´m (45 ft. lbs.).
(6) Install the fan blade, fan clutch and fan
shroud.
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A.008 mm U/S 63.488-63.496 mm
(.0004 in.)
U/S(2.4996-2.4999 in.)
BSTANDARD 63.496-63.504 mm
(2.4996-2.4999 in.)
C.008 mm O/S 63.504-63.512 mm
(.0004 in.)
O/S(2.5002-2.5005 in.)
Fig. 32 Engine Insulator Mount 4x2 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 33 Engine Insulator Mount 4x2 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
9 - 28 4.7L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine ENGINE MOUNTÐREAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nut from the insulator mount
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).(4) Remove the four bolts and washers retaining
the mount to the transmission (4x4 automatic trans-
mission only) (Fig. 38).
(5) Raise the transmission enough to remove the
through bolt (Manual transmission and 4x2 auto-
matic transmission only) (Fig. 36) (Fig. 37).
(6) Raise the transmission and remove the bolts
retaining the mount to the crossmember (4x4 auto-
matic transmission only) (Fig. 38).
(7) Remove the two nuts retaining the isolator to
the crossmember (Manual transmission and 4x2
automatic transmission only) (Fig. 36) (Fig. 37).
(8) Remove the bolts (two bolts manual transmis-
sion)(three bolts 4x2 automatic transmission) retain-
ing the insulator bracket to the transmission.
INSTALLATION
(1) Follow the removal procedure in the reverse
order.
(2) Tighten the through bolt retaining nut to 102
N´m (75 ft. lbs.).
(3) Tighten the isolator bracket to transmission
retaining bolts (Manual transmission and 4x2 auto-
matic transmission only) to 41 N´m (30 ft. lbs.).
(4) Tighten the mount bracket to transmission
retaining bolts (4x4 automatic transmission only) to
68 N´m (50 ft. lbs.).
(5) Tighten the isolator mount to crossmember
retaining nuts (Manual transmission and 4x2 auto-
matic transmission only) to 28 N´m (250 in. lbs.).
Fig. 34 Engine Insulator Mount 4x4 VehicleÐLeft
Side
1 ± ENGINE INSULATOR MOUNT-LEFT SIDE
2 ± MOUNTING BOLT
Fig. 35 Engine Insulator Mount 4x4 VehicleÐRight
Side
1 ± ENGINE INSULATOR MOUNT-RIGHT SIDE
2 ± MOUNTING BOLT
Fig. 36 Engine Rear MountÐ4X2 Automatic
Transmission
1 ± ENGINE REAR MOUNT
2 ± BOLT
3 ± NUT
4 ± THROUGH BOLT NUT
5 ± TRANSMISSION
DN4.7L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine (6) Tighten the mount bracket to crossmember
retaining bolts (4x4 automatic transmission only) to
28 N´m (250 in. lbs.).
STRUCTURAL COVER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold. Refer to Group 11, Exhaust Sys-
tem.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 39).
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed
as described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 39) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 39) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
Fig. 37 Engine Rear MountÐ4X2 and 4X4 Manual
Transmission
1 ± THROUGH BOLT
2 ± BOLT
3 ± INSULATOR SUPPORT
4 ± NUT
5 ± NUT AND WASHER
6 ± INSULATOR BRACKET TO TRANSMISSION
Fig. 38 Engine Rear MountÐ4X4 Automatic
Transmission
1 ± TRANSMISSION
2 ± ENGINE REAR MOUNT
3 ± BOLT
Fig. 39 Structural Cover
9 - 30 4.7L ENGINEDN
REMOVAL AND INSTALLATION (Continued)